Audi Workshop Service and Repair Manuals

Removing and installing sump Special tools and workshop equipment required

t  Used oil collection and extraction unit -V.A.G 1782- t  Electric drill with plastic brush attachment t  Safety goggles t  Sealant → Electronic parts catalogue

Removing –  Disconnect secondary air hose at the position marked with an -arrow-.

–  Remove centre noise insulation -fasteners 1 ... 3-.

–  Remove noise insulation (right-side) -fasteners 1 ... 3-. –  Drain off engine oil.

–  Move coolant hose at bottom of radiator cowl clear. –  Detach electrical connector -3- at secondary air pump motor -V101- and move wire clear. –  Unscrew bracket -2- for coolant pipe going to gearbox oil cooler on vehicles with direct shift gearbox. –  Remove bolts -1-. –  Loosen bolt -4- and remove secondary air pump with bracket.

–  Unplug electrical connector -1- at oil level and oil temperature sender -G266-. –  Unscrew sump/gearbox bolts -arrows-. –  Unscrew bolts for sump -2- in diagonal sequence and remove. –  Take off sump; if necessary loosen it by striking lightly with a rubber hammer. Installing l  Tightening torques → Chapter, → Fig.. Installation is carried out in the reverse order; note the following:

–  Carefully remove sealant residue from cylinder block.   WARNING Protect eyes against injuries. Wear safety goggles. –  Remove sealant residue from sump, e.g. with rotating plastic brush or similar. –  Clean sealing surfaces; they must be free of oil and grease.

–  Cut off tube nozzle at front marking (nozzle approx. 2 mm Ø).

–  Apply the sealant onto the clean sealing surface of the sump as illustrated -arrow-. l  Width of sealant bead: 2 mm.   Caution Make sure oil strainer is not clogged by excess sealant. The bead of sealant must not be thicker than specified.   Note t  Take extra care when applying sealant bead in the area around the lower cover for timing chains. t  The sump must be installed within 5 minutes after applying sealant.

–  Tighten bolts securing sump -2- → Fig.. 1 -  –  Plug in electrical connector -1- for oil level and oil temperature sender -G266-.   Caution Take care to avoid leakage at sump. After fitting sump assembly, the sealant must dry for approx. 30 minutes. Then (and only then) fill the engine with engine oil. –  Fill up with engine oil and check oil level → Chapter.